Calcutta post production factory adjustments

Started by exp2000, June 06, 2018, 11:48:58 AM

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exp2000

Just did a run of Calcutta 200B reels.

There was a washer left over on the first reel which I did not recognize.

I could only find two places where it could possibly fit. I decided both of these were unlikely and settled on a third which tested good and whilst rather peculiar, I had to admit made more sense than the other options.

The next reel confirmed my suspicions. Another case of post production remedial measures to correct poor manufacturing tolerances. Without the washer the clutch trip pawl would kick up against the anti-reverse ratchet cog making a clicking noise when the handle was cranked.

But wait, there's more! There was also another foreign washer not depicted in the schematics under spacer 664 (beneath the LHS bearing) which would adjust the spool position affecting line lay on the spool.

While I neglected to take measurements, I estimate both washers to be approximately 0.3mm in thickness.
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ReelClean

Calcutta 200B  Hardware Update 1.63. 
You would think it would be cheaper to make it to spec in the first place than muck around with shims.  I wonder how many fell off the production line before someone tested one and found the problem, then when the milling machine was adjusted to fix it?
Specialist Daiwa reel service, including Magseal.

rippin_lips

Quote from: ReelClean on June 06, 2018, 11:18:14 PM
Calcutta 200B  Hardware Update 1.63. 
You would think it would be cheaper to make it to spec in the first place than muck around with shims.  I wonder how many fell off the production line before someone tested one and found the problem, then when the milling machine was adjusted to fix it?

No it's very expensive to improve on dimensional tolerances, the costs grow exponentially not linearly.  The cost for tightening dimensional tolerances, is seen in any every day items.  Ever wondered why two products from the same company can be amazing or crap?  Automobiles are a good example.  Take two of the same make and model vehicles, and one might drive 200,000 miles without a hitch and the other will be in the shop on week 1.  Tolerances stack up and it's possible for one product coming off an assembly line to get a combination of parts on opposite ends of the tolerance ranges and they all come together to fail spectacularly even though they were all "in spec".